Swegon CELEST+ Maintenance Manual

1

Celest+

User and maintenance manual 14-05-2013

2

1

Contents

1

11

1

INTRODUCTION

INTRODUCTIONINTRODUCTION

INTRODUCTION

................................

................................................................

...............................................

..............................

...............

3

33

3

2

22

2

SYMBOLS

SYMBOLSSYMBOLS

SYMBOLS

................................

................................................................

........................................................

................................................

........................

3

33

3

33

3

FIELD OF APPLICATION

FIELD OF APPLICATIONFIELD OF APPLICATION

FIELD OF APPLICATION

................................

................................................................

.....................................

..........

.....

4

44

4

3.1

O

VERVIEW

......................................................................................................................................................... 4

4

44

4

INSPECTION, UNPACKIN

INSPECTION, UNPACKININSPECTION, UNPACKIN

INSPECTION, UNPACKING, TRANSPORT

G, TRANSPORTG, TRANSPORT

G, TRANSPORT

................................

................................................................

............................................

........................

............

4

44

4

4.1

I

NSPECTION

........................................................................................................................................................ 4

4.2

U

NPACKING

....................................................................................................................................................... 4

4.3

L

IFTING AND TRANSPORT

....................................................................................................................................... 4

5

55

5

UNINTENDED USE

UNINTENDED USEUNINTENDED USE

UNINTENDED USE

................................

................................................................

............................................

........................

............

5

55

5

6

66

6

SAFETY MEASURES

SAFETY MEASURESSAFETY MEASURES

SAFETY MEASURES

................................

................................................................

..........................................

....................

..........

6

66

6

6.1

D

EFINITION OF DANGEROUS AREA

............................................................................................................................ 6

6.2

S

AFETY PROVISIONS

.............................................................................................................................................. 6

6.3

I

NSTALLATION IN AREAS WITH EXPLOSIVE ATMOSPHERES

............................................................................................... 6

6.4

P

ROTECTIVE DEVICES

............................................................................................................................................ 6

6.5

L

IGHTING

........................................................................................................................................................... 7

6.6

PERSONNEL

QUALIFICATIONS

–

OBLIGATIONS ................................................................................................. 7

6.7

V

ARIOUS WARNINGS

............................................................................................................................................ 7

7

77

7

POSITIONING AND INST

POSITIONING AND INSTPOSITIONING AND INST

POSITIONING AND INSTALLATION

ALLATIONALLATION

ALLATION

................................

................................................................

.....................................................

..........................................

.....................

7

77

7

7.1

S

PACES FOR INSTALLATION

..................................................................................................................................... 8

7.2

A

NTI

-

VIBRATION MOUNTS

(

OPTIONAL

) ...................................................................................................................... 8

7.2.1

Rubber anti-vibration mounts ....................................................................................................................... 8

7.3

G

ENERAL RECOMMENDATIONS FOR HYDRAULIC CONNECTIONS

...................................................................................... 9

7.3.1

Recommended hydraulic circuit ................................................................................................................. 10

7.3.2

ST 1P - ST 1PM - ST 1PV set-ups................................................................................................................. 10

7.3.3

ST 1PS - ST 1PMS - ST 1PVS set-ups ........................................................................................................... 11

8

88

8

HYDRAULIC CONNECTION

HYDRAULIC CONNECTIONHYDRAULIC CONNECTION

HYDRAULIC CONNECTION

................................

................................................................

..............................................................

............................................................

..............................12

1212

12

8.1

H

YDRAULIC CONNECTION TO THE EXCHANGER

......................................................................................................... 12

8.2

M

INIMUM WATER CONTENT IN THE PLANT

. .............................................................................................................. 12

8.3

I

NSTRUCTIONS FOR MOUNTING THE WATER FLOW METER

............................................................................................ 12

8.4

W

ATER FLOW RATE TO THE EXCHANGERS

................................................................................................................ 13

8.5

C

OMPOSITION OF THE WATER

............................................................................................................................... 14

8.6

O

PERATION WITH WATER TO THE EVAPORATOR AT LOW TEMPERATURE

(

CHILLER UNIT

)....................................................... 14

8.7

O

PERATION WITH WATER TO THE CONDENSER AT LOW TEMPERATURE

(

HEAT PUMP UNIT

) ................................................... 15

8.8

D

ISCHARGE OF THE SAFETY VALVES

........................................................................................................................ 15

9

99

9

CONNECTIONS FOR SPLI

CONNECTIONS FOR SPLICONNECTIONS FOR SPLI

CONNECTIONS FOR SPLIT UNITS

T UNITST UNITS

T UNITS

................................

................................................................

......................................................

............................................

......................15

1515

15

9.1

C

OOLING CONNECTIONS

..................................................................................................................................... 15

9.2

S

ET

-

UPS FOR THE REALISATION OF THE REFRIGERANT LINES

........................................................................................... 15

9.3

LE

VERSIONS

:

EVAPORATING SECTION AT A LEVEL LOWER THAN THAT OF THE CONDENSING SECTION

. .................................... 15

9.4

LE

VERSIONS

:

EVAPORATING SECTION AT A LEVEL HIGHER THAN THAT OF THE CONDENSING SECTION

. ................................... 16

9.5

LE/HP

VERSIONS

:

EVAPORATING

/

CONDENSING SECTION AT A LEVEL LOWER THAN THAT OF THE CONDENSING

/

CONDENSERLESS

SECTION

. ................................................................................................................................................................... 16

9.6

LE/HP

VERSIONS

:

EVAPORATING

/

CONDENSING SECTION AT A LEVEL HIGHER THAN THAT OF THE CONDENSING

/

CONDENSERLESS

SECTION

. ................................................................................................................................................................... 17

9.7

V

ARIATION IN CAPACITY IN RELATION TO THE LENGTH OF THE COOLING LINES

.................................................................. 17

9.8

R

EFRIGERANT LOAD FOR

LE

AND

LE/HP

UNITS

.......................................................................................................... 18

10

1010

10

ELECTRICAL CONNECTIO

ELECTRICAL CONNECTIOELECTRICAL CONNECTIO

ELECTRICAL CONNECTIONS

NSNS

NS

................................

................................................................

.........................................................

..................................................

.........................18

1818

18

10.1

O

VERVIEW

.................................................................................................................................................... 18

10.2

P

OWERING THE RESISTANCES OF THE COMPRESSOR GUARD

...................................................................................... 19

10.3

P

OTENTIAL FREE CONTACTS

.............................................................................................................................. 19

10.4

C

IRCULATION PUMP ELECTRIC CONNECTIONS

........................................................................................................ 19

10.5

C

ONTROL OF THE FANS SPEED

........................................................................................................................... 19

10.6

M

ICROPROCESSOR CONTROL

............................................................................................................................ 20

11

1111

11

START

STARTSTART

START-

--

-UP

UPUP

UP

................................

................................................................

....................................................

........................................

....................20

2020

20

11.1

P

RELIMINARY VERIFICATIONS

............................................................................................................................. 20

2

11.2

V

ERIFICATIONS DURING OPERATION

.................................................................................................................... 20

11.3

C

HECKING THE REFRIGERANT LOAD

.................................................................................................................... 20

11.4

A

LARMS

....................................................................................................................................................... 21

12

1212

12

CALIBRATING THE CONT

CALIBRATING THE CONTCALIBRATING THE CONT

CALIBRATING THE CONTROL COMPONENTS

ROL COMPONENTSROL COMPONENTS

ROL COMPONENTS

................................

................................................................

................................

21

2121

21

13

1313

13

DECOMMISSIONING

DECOMMISSIONINGDECOMMISSIONING

DECOMMISSIONING

................................

................................................................

....................................

........

....

21

2121

21

13.1

S

EASONAL SHUTDOWN

.................................................................................................................................... 21

13.2

E

MERGENCY STOP

.......................................................................................................................................... 21

14

1414

14

PERIODIC MAINTENANCE

PERIODIC MAINTENANCEPERIODIC MAINTENANCE

PERIODIC MAINTENANCE

AND INSPECTIONS

AND INSPECTIONSAND INSPECTIONS

AND INSPECTIONS

................................

................................................................

................................

22

2222

22

14.1

W

ARNINGS

................................................................................................................................................... 22

14.2

O

VERVIEW

.................................................................................................................................................... 23

14.3

P

ROTECTION OF THE ENVIRONMENT

.................................................................................................................... 23

15

1515

15

DISPOSAL OF THE UNIT

DISPOSAL OF THE UNITDISPOSAL OF THE UNIT

DISPOSAL OF THE UNIT

................................

................................................................

................................

23

2323

23

16

1616

16

REFRIGERANT

REFRIGERANTREFRIGERANT

REFRIGERANT

................................

................................................................

..............................................

............................

..............

23

2323

23

16.1

R410A

REFRIGERANT

SAFETY

DATA

SHEETS ............................................................................................... 23

16.2

IMPORTANT

INFORMATION

REGARDING

THE

REFRIGERANT

USED ............................................................. 25

3

1

11

1 INTRODUCTION

INTRODUCTION INTRODUCTION

INTRODUCTION

For construction features, available models and technical data refer to the technical booklet.

The model, serial number, features, power supply voltage etc. are shown on the labels affixed to the machine (the

following images serve as an example).

The Manufacturer has a policy for constant improvement and reserves the right to make

changes and improvements to the documentation of the machines without prior notice.

The technical booklet and the labels affixed directly on the machine are to be considered an

integral part of this manual.

2

22

2 SYMBOLS

SYMBOLSSYMBOLS

SYMBOLS

Below is a description of the main symbols used in this manual and on the labels affixed on the unit.

Danger symbol; take extreme care.

Danger symbol; moving mechanical parts.

Danger symbol; live components.

4

3

33

3 FIELD OF APPLICATION

FIELD OF APPLICATIONFIELD OF APPLICATION

FIELD OF APPLICATION

The "hydronic" version is intended for the cooling/heating of water generally for applications in the field of air-

conditioning. The "condensing" and "reversible condensing" versions of the machines are to be connected to

ventilating units with direct expansion coils for the cooling/heating of air; the coils and connecting pipes must be

designed for use with R410A.

They must be used within the operating limits indicated in the Technical Booklet.

3.1

3.13.1

3.1 Overview

OverviewOverview

Overview

Upon installation or whenever interventions must be performed on the refrigeration unit, it is essential to carefully

follow the instructions in this manual, comply with the indications shown on board the unit and apply all

precautions required.

The pressures in the hydraulic circuit and the electrical components can create risky situations during installation and

maintenance interventions.

Any intervention on the unit must be performed by qualified authorised personnel.

Warning: before performing any intervention on the unit make sure that the power supply

has been disconnected. Refer to the section on maintenance.

Failure to comply with the instructions in this manual and any modification to the unit without written consent, will

immediately render the warranty null and void.

4

44

4 INSPECTION, UNPACKING, TRANSPORT

INSPECTION, UNPACKING, TRANSPORTINSPECTION, UNPACKING, TRANSPORT

INSPECTION, UNPACKING, TRANSPORT

4.1

4.14.1

4.1 Inspection

InspectionInspection

Inspection

Check the unit upon receipt, bearing in mind that it left the factory in perfect condition; report any signs of damage

immediately to the transporter and make a note of these on the Delivery Sheet before signing it.

The commercial office or manufacturer should be informed of the extent of the damage as soon as possible.

The Customer must fill in a written and photographic report concerning any relevant damage.

4.2

4.24.2

4.2 Unpacking

UnpackingUnpacking

Unpacking

Disposal of packing material is the responsibility of the receiver and must be carried out in compliance with local

and national regulations.

4.3

4.34.3

4.3 Lifting and transport

Lifting and transportLifting and transport

Lifting and transport

During unloading and positioning of the unit, great care must be given to prevent sudden or violent manoeuvres

and not using machine components as strong points. Lift the unit using steel tubes inserted in the relative lifting

holes. The unit must be lifted by harnessing it as indicated in figure 1. Use cords or belts that are long enough and

spacer bars so as not to damage the sides and lid of the unit. Alternatively, the units can be lifted using a fork-lift

truck, inserting the forks in the supporting pallet (fig. 1).

Attention: In all lifting operations, make sure that the unit is fastened well in order to

prevent accidental falls or over-turning.

5

Fig. 1

The means of lifting, the ropes and harnesses must be selected by staff with suitable specific

knowledge and able to assume all responsibilities relative to their use.

Keep the forks low. Use ballasts in the event of unbalancing. Do not hold protruding parts

with your hands.

It is prohibited to pass under or near the load.

The unit must be transported by qualified personnel (forklift operator, slinging personnel),

who must wear the necessary personal protective equipment (overalls, safety shoes, work

gloves, hard hats, goggles).

The Manufacturer declines all responsibility for any accident caused by non compliance with

this warning.

5

55

5 UNINTENDED USE

UNINTENDED USEUNINTENDED USE

UNINTENDED USE

The machine must not be used:

– in an explosive atmosphere;

– in an inflammable atmosphere;

– in extremely dusty environments;

– by untrained personnel;

– in non-compliance with the Standards in force;

– with improper installation;

– with power supply defects;

– with total or partial failure to comply with the instructions;

– with lack of maintenance and/or use of non-original spare parts;

– with modifications or other interventions not authorised by the Manufacturer;

– when the work area is not kept free from tools and other objects;

– when the work area is not clean enough;

– in presence of abnormal vibrations in the work area.

6

66

6 SAFETY MEASURES

SAFETY MEASURESSAFETY MEASURES

SAFETY MEASURES

The machine complies with Directives 2006/42 EC, 2004/108 EC, 2006/95 EC and 97/23 EC and applicable

Technical Standards as stipulated in the Declaration of Conformity that constitutes an integral part of this manual.

6.1

6.16.1

6.1 Definition of dangerous area

Definition of dangerous areaDefinition of dangerous area

Definition of dangerous area

The machine must be accessed only by authorised operators.

– The external dangerous area is identified by a space of about 2 metres around the machine. If the unit is

positioned in an unprotected place, which can be easily reached by unqualified personnel, access to this area

must be prohibited by a special protection.

– The internal dangerous area can be accessed by entering the machine. For no reason must access inside the

machine be allowed to unqualified personnel and before having disconnected the voltage.

6.2

6.26.2

6.2 Safety provisions

Safety provisionsSafety provisions

Safety provisions

All the units are designed and built in compliance with the Pressure Equipment Directive (97/23 EC), so as to ensure

maximum safety. Comply with the following provisions in order to prevent possible risks:

– this product contains pressurised parts, live components, moving mechanical components and surfaces at

extreme temperatures that, in certain situations, can pose a risk: all maintenance must be entrusted to

qualified personnel with the necessary authorisation, in accordance with the regulations in force. Before

carrying out any operation, make sure that the appointed personnel has full knowledge of the documentation

supplied with the unit.

– Always have a copy of the documentation near the unit.

– The operations shown in this manual must be integrated with the procedures found in the user instruction

manuals of the other systems and devices incorporated in the machine. The manuals contain all the necessary

information to handle the devices safely and the possible operating modes.

– Use the suitable protection (gloves, helmet, protective glasses, accident-prevention shoes etc.) for any

maintenance or control operation performed on the unit.

– Do not wear loose clothing, ties, chains, watches, etc., which can get caught in moving machine parts.

– Always use tools and protective equipment in excellent state.

– There are very hot parts in the compressor compartment; be careful, therefore, when working in the

immediate vicinity not to touch any components of the unit without the necessary protection.

– Do not operate in the drain path of the safety valves.

– If the units are positioned in places that are not protected and can be easily reached by unqualified persons it is

mandatory to install suitable protections.

– The user is obliged to consult the installation and use manuals of the systems, incorporated and attached to

this manual.

– There may be potential risks that are not evident. Warning and signs are therefore envisioned in the machine.

– It is prohibited to remove the warnings.

It is forbidden to:

– remove or make safety guards ineffective;

– tamper with and/or modify, even partially, the safety devices installed on the machine

If an alarm is signalled and consequently the safety devices are activated, the operator must request the immediate

intervention of qualified maintenance technicians. Any accident can lead to serious injury or death.

The safety devices must be checked according to the guidelines found in the attached instruction manuals.

Verification and inspections must be performed by persons who are authorised in writing by the employer.

A copy of the verification results must be left on the machine or in its proximity. Any accident can lead to serious

injury or death.

The manufacturer does not assume any liability for damage/injury to persons, pets or objects deriving from the re-

use of individual parts of the machine for functions of assembly different to the original situation. It is prohibited to

tamper with/replace one or more parts of the machine without authorisation.

The use of accessories, tools or consumables other than those recommended by the Manufacturer relieves the latter

from civil or criminal liability.

Machine decommissioning and demolition must be carried out by suitably trained and equipped personnel.

6.3

6.36.3

6.3 Installation in areas with explosive atmospheres

Installation in areas with explosive atmospheresInstallation in areas with explosive atmospheres

Installation in areas with explosive atmospheres

The machines do not fall under the application field of the ATEX Directive 94/9/EC – Presidential Decree n. 126 of

23/3/98.

6.4

6.46.4

6.4 Protective devices

Protective devicesProtective devices

Protective devices

The machine is equipped with technical protection measures against hazards that cannot be reasonably eliminated

or sufficiently limited through design.

It is forbidden to:

– remove or make safety guards ineffective;

7

– tamper with and/or modify, even partly, the safety devices installed on the machine.

6.5

6.56.5

6.5 Lighting

LightingLighting

Lighting

This should make it possible to carry out installation and maintenance without incurring risks due to areas of

darkness.

6.6

6.66.6

6.6 PERSO

PERSOPERSO

PERSONNEL QUALIFICATIONS

NNEL QUALIFICATIONS NNEL QUALIFICATIONS

NNEL QUALIFICATIONS –

––

–

OBLIGATIONS

OBLIGATIONSOBLIGATIONS

OBLIGATIONS

The user must know and apply the prescriptions regarding occupational safety, in compliance with Directives

89/391/EC and 1999/92/EC.

The knowledge and comprehension of the manual are indispensable for reducing risks and for improving the health

and safety of the workers.

The operator must have a suitable degree of education to perform the various activities throughout the technical

lifespan of the machine.

The operator must be trained on possible anomalies, malfunctions or dangerous conditions

for himself or others and in any case, he must comply with the following prescriptions:

- stop the machine immediately by acting on the emergency button/s;

- refrain from any intervention that goes beyond his duties and technical knowledge;

- inform the manager immediately and do not take personal initiatives.

6.7

6.76.7

6.7 Various warnings

Various warningsVarious warnings

Various warnings

Comply with the regulations in force concerning the safety devices on the machine and the personal protective

equipment.

The Technical File is maintained at the manufacturer's location.

The manufacturer does not assume any liability for any damage/injury to persons, pets or objects deriving from the

failure to comply with the Safety Standards and recommendation contained in the documentation supplied.

In addition to this manual are other documents and labels affixed directly on the machine that also provide

important information. Consult these other documents when required.

7

77

7

POSITIONING AND INSTALLATION

POSITIONING AND INSTALLATIONPOSITIONING AND INSTALLATION

POSITIONING AND INSTALLATION

The following must be taken into account when choosing the unit’s place of installation and making the relative

connections:

– size and origin of the hydraulic piping;

– location of the power supply;

– accessibility for maintenance or repair operations;

– solidity of the support surface;

– ventilation of the air-cooled condenser;

– orientation and exposure to solar radiation: keep the condensing coil out of direct sunlight whenever possible;

– do not position the unit in a way that strong winds favour air recirculation at the condensing coil;

– do not position the machine on dark coloured land (e.g. tarred surfaces) so as not to cause functioning

overheating;

– possible sound reverberation.

It is obligatory to observe the clearances specified in the dimensional drawing of the unit.

The unit must always be anchored to the ground.

Provide a solid base on which to position the unit. This support must be perfectly flat and horizontal. Its dimensions

must be suitable for those of the unit. This precaution is indispensable when the unit is to be positioned on unstable

ground (various lands, gardens etc.). Figure 2 illustrates the structure of a typical support slab.

8

Fig. 2

The slab must be:

– made in suitable foundation with a height of about 15-20 cm with respect to the surrounding land,

– supplied with a cork gasket suitably sealed along the perimeter,

– flat, horizontal and able to support 150% of the operational weight of the machine.

– at least 30 cm longer and wider than the machine.

Although the unit transmits low levels of vibrations to the supporting structure, it is advisable to lay a sheet of hard

rubber between the base of the unit and the supporting surface.

If better insulation is required, it is advisable to use the anti-vibration supports which are available as accessories.

In the event of installation on roofs or intermediate floors, the unit and the piping must be isolated from the walls

and ceilings. The units should not be positioned in proximity of private offices, bedrooms or areas where low sound

emissions are required. To prevent excessive sound reverberation, do not install the unit in narrow or confined

spaces.

The machine equipped with standard coils should not be installed in an environment where there is an aggressive

chemical atmosphere, in order to avoid the risk of corrosion.

Particular care should be taken to avoid atmospheres containing sodium chloride, which can aggravate corrosion

due to galvanic currents; a machine with untreated coils must not, for any reason, be installed in a marine

environment.

In the case of a marine or highly polluting industrial environment, it is necessary to request coils with anti-corrosion

surface treatment or copper-copper or copper-tinned copper coils.

In any case, please contact our commercial office to define the most suitable solution.

7.1

7.17.1

7.1 Spaces for installation

Spaces for installationSpaces for installation

Spaces for installation

The service spaces to comply with are shown on the dimensional drawings attached to the documentation of the

machine.

The condensing coil must be allowed adequate space for the airflow at both the intake and the exhaust side.

In order to prevent poor unit capacity or even interruptions in unit operation it is absolutely essential to avoid the

recirculation of air between the intake and the exhaust.

High walls near the unit may interfere with its proper functioning.

Units should be installed a minimum of three metres apart.

It is advisable to leave sufficient space between the units for removing their larger components such as the

exchangers, compressors or pumps.

7.2

7.27.2

7.2 Anti

AntiAnti

Anti-

--

-vibration mounts (optional)

vibration mounts (optional)vibration mounts (optional)

vibration mounts (optional)

In order to reduce vibrations transmitted to the structure, it is recommended to install the machine on rubber or

spring anti-vibration mounts, supplied as an accessory.

The dimensional layout with the contact patch, attached to the machine, shows the position and load of each anti-

vibration mount.

The anti-vibration mounts must be applied before positioning the machine on the ground.

7.2.1

7.2.17.2.1

7.2.1

Rubber anti

Rubber antiRubber anti

Rubber anti-

--

-vibration mounts

vibration mountsvibration mounts

vibration mounts

The anti-vibration mount consists of an upper metal bell in which there is a screw to fasten the unit base. The anti-

vibration mount is fastened to the base through the two holes on the flange. The anti-vibration flange bears a

number (45,60,70 ShA) that identifies the hardness of the rubber support.

The dimensional layout with the contact patch, attached to the machine, shows the position and load of each anti-

vibration mount.

Slab

Sealant

Cork gasket

Land

15

–

20 cm

9

Fig. 3: Rubber/metal anti-vibration mounts, particularly suitable to dampen the vibration stress.

7.3

7.37.3

7.3 General recommendations for hydraulic connections

General recommendations for hydraulic connectionsGeneral recommendations for hydraulic connections

General recommendations for hydraulic connections

When setting up the hydraulic circuit for the evaporator, it is good practice to comply with the following

prescriptions and in any case with the national and local regulations (refer to the layouts included in the manual).

fit the piping to the chiller using flexible joints in order to prevent transmission of the vibrations and compensate

heat dilation. (Proceed on the pumps unit in the same way).

Install the following components on the piping:

– stop cocks, temperature and pressure indicators for routing maintenance and unit inspection.

– sample points on the input and output pipes to read the temperature, if temperature indicators are not

present.

– shut-off valves (gate valves) to isolate the unit from the hydraulic circuit.

– metal mesh filter with openings not wider than 1 mm, on the exchanger inlet pipe to protect the exchanger

against slag or impurities in the pipes.

– vent valves, to locate in the highest parts of the hydraulic circuit, in order to allow to bleed the non-

condensables.

– expansion tank and automatic charging valve for maintenance of the system pressure and to compensate heat

dilation.

– drain valve and where necessary, drain tank to empty the system for maintenance operations or seasonal

breaks.

It is mandatory to comply with these prescriptions to facilitate the hydraulic connection

operations, maintenance and access to the electrical panel.

It is highly recommended to install a safety valve on the hydraulic circuit. If serious anomalies

should arise in the system (e.g. a fire breaks out), this allows the system to be drained,

thereby preventing any explosion.

Always connect the drain to a pipe with a diameter that is no less than that of the valve

opening and direct it towards the areas where the jet cannot harm anyone.

It is mandatory to install the flow meter supplied with the unit in line with the chilled water

outlet connection.

It is obligatory to assemble the metal mesh filter on the water inlet pipe. If any of the above

are missing, the warranty is cancelled immediately.

It is highly recommended to install a safety valve on the hydraulic circuit. In the event of

serious anomalies in the system (e.g. fire) it allows to drain the system, thus preventing any

explosions.

Always connect the drain to a pipe with a diameter that is no less than that of the valve

opening and direct it towards the areas where the jet cannot harm anyone.

Use two keys to tighten the hydraulic connections (see fig. 3).

10

Fig. 3

7.3.1

7.3.17.3.1

7.3.1 Recommended hydraulic circuit

Recommended hydraulic circuit Recommended hydraulic circuit

Recommended hydraulic circuit

01 Circulation pump

02 Expansion tank

04 Non-return valve

05 Ball cock

06 Tank

07 Manometer

08 Thermometer

09 Water filter

10 Bleed valve

11 Flexible coupling

12 Plant filling unit

13 Water outlet

14 Flow meter

19 Safety valve

7.3.2

7.3.27.3.2

7.3.2 ST 1P

ST 1P ST 1P

ST 1P -

--

-

ST 1PM

ST 1PM ST 1PM

ST 1PM -

--

-

ST 1PV set

ST 1PV setST 1PV set

ST 1PV set-

--

-ups

upsups

ups

03 Evaporator

17 Electrical heater

CR Heating cable

EL Electric pump

FL Flow meter

RB Cock

PA Well for anti-freeze probe

Utility

water

inlet

Utility

water

outlet

Source side

exchanger

11

PF Well for water inlet probe

SA Safety valve

RE Tank electrical heater

SB Storage tank

SF Bleed valve

VE Expansion tank

7.3.3

7.3.37.3.3

7.3.3 ST 1PS

ST 1PS ST 1PS

ST 1PS -

--

-

ST 1PMS

ST 1PMS ST 1PMS

ST 1PMS -

--

-

ST 1PVS set

ST 1PVS setST 1PVS set

ST 1PVS set-

--

-ups

upsups

ups

03 Evaporator

17 Electrical heater

CR Heating cable

EL Electric pump

FL Flow meter

RB Cock

PA Well for anti-freeze probe

PF Well for water inlet probe

SA Safety valve

RE Tank electrical heater

SB Storage tank

SF Bleed valve

VE Expansion tank

12

8

88

8 HYDRAULIC CONNECTION

HYDRAULIC CONNECTIONHYDRAULIC CONNECTION

HYDRAULIC CONNECTION

8.1

8.18.1

8.1

Hydra

HydraHydra

Hydraulic connection to the exchanger

ulic connection to the exchangerulic connection to the exchanger

ulic connection to the exchanger

It is of fundamental importance that the water inlet is installed where the connection is

marked with the following plate:

CHILLED WATER

Otherwise, the evaporator could freeze as the anti-freeze thermostat check would be

annulled.

If the integrated inverter is not provided with the machine (i.e. is supplied directly by the

manufacturer), the hydraulic circuit should be set up in such a way as to guarantee a

constant flow of water to the exchanger in all operating conditions. If this is not the case,

the risk of refrigerant returning in the liquid state to the compressor input would be run,

with the danger of breakage of the same.

Warning: during the hydraulic connections, never operate with naked flames near or inside

the unit.

8.2

8.28.2

8.2 Minimum water content in the plant.

Minimum water content in the plant.Minimum water content in the plant.

Minimum water content in the plant.

The compressors can run intermittently; this is because the amount of cooling power required by the unit is not

generally the same as that provided by the machine.

It is necessary to guarantee inertia on the system such to limit oscillation of the water temperature within the limits

that do not compromise the good functioning of the unit and, at the same time, guarantee good stability at the

water flow temperature. The mathematical formula below is for calculating the minimum water content on the side

of the plant:





 



  4





: water content of the plant [l]





: Power capacity of the unit [kW]

If the above mentioned volumes are not reached, a storage tank must be set up for its capacity together with that

of the system to reach the relative value



.

This tank does not require particular set-ups. It must however be carefully isolated like all chilled water pipes, in

order to prevent condensation and not to affect system performance.

8.3

8.38.3

8.3 Instructions for mounting the water flow meter

Instructions for mounting the water flow meterInstructions for mounting the water flow meter

Instructions for mounting the water flow meter

– Clean the pipes making sure that any metal residue cannot interfere with correct operation of the flow meter.

– Connect the flow meter to the male threaded outlet coupling on the evaporator (fig. 4) bearing this label:

Seal the connection with Teflon tape.

13

Fig. 4

– Make sure that the flow meter (plastic body) is securely fastened on the metal coupling with the plastic locking

ring, and that the arrow on the flow meter points in the direction of the flow of water.

– Make sure to put the O-ring seal between the locking ring and the metal fitting. The O-ring is provided in the

plastic cover that protects the rod of the flow meter.

– Connect the hydraulic circuit to the other end of the "T" fitting.

– Feed the electrical cable of the flow meter through the hole in the structural steelwork and connect the flow

meter to the terminals in the electric control board as indicated in the electrical diagram.

– To disassemble the flow meter, unscrew the plastic locking ring. When reassembling the flow meter, put the

ring seal between the metal fitting and the plastic part (see fig. 5).

Fig. 5

8.4

8.48.4

8.4 Water flow rate to the exchangers

Water flow rate to the exchangersWater flow rate to the exchangers

Water flow rate to the exchangers

The nominal water flow rate refers to a thermal gradient of 5 °C between the inlet and outlet.

The maximum water flow rate refers to a thermal gradient of 4 °C: anything higher could cause too great a

pressure drop and the risk of damage to the evaporator.

The minimum flow rate accepted is that with a pressure drop no less than 10 kPa. Lower flow rate values could

cause evaporation temperatures that are too low with safety intervention and unit stop.

In any case, refer to the specific Technical Booklet for the permitted conditions for the flow of water in and out of

the exchangers.

14

8.5

8.58.5

8.5 Composition of th

Composition of thComposition of th

Composition of the water

e watere water

e water

Dissolved substances in the water can cause corrosion in the heat exchangers. It is mandatory to verify that the

water parameters comply with this table:

Total hardness

2.0 to 6.0 °F

Langelier index

-

0.4 to + 0.4

pH

7.5 to 8.5

Electrical

conductivity

10 to 500 S/cm

Organic elements

-

Hydrogen carbonate (HCO

3

-

)

70 to 300 ppm

Sulphates (SO

4

2

-

)

< 50 ppm

Hydrogen carbonate / Sulphates (HCO

3

-

/SO

4

2

-

)

> 1

Chlorides ( Cl

-

)

< 50 ppm

Nitrates (NO

3

-

)

< 50 ppm

Sulphuric acid (H

2

S)

<

0.05 ppm

Ammonia (NH

3

)

< 0.05 ppm

Sulphites (SO

3

), free chlorine (Cl

2

)

< 1 ppm

Carbon dioxide (CO

2

)

< 5 ppm

Metal cations

< 0.2 ppm

Manganese ions ( Mn

++

)

< 0.1 ppm

Iron ions ( Fe

2+

, Fe

3+

)

< 0.2 ppm

Iron + Manganese

< 0.5 ppm

Phosphates (PO

4

3

-

)

< 2 ppm

Oxygen

< 0.1 ppm

If water is used that does not meet the criteria in the table, the warranty is immediately rendered null and void.

It is mandatory to set up a system that eliminates the possible organic substances in the water that could pass

through the filter and settle in the heat exchangers, which would lead to malfunction and/or damage in time.

If the water used in the unit contains organic substances, the warranty is immediately rendered null and void.

8.6

8.68.6

8.6 Operation with water to the evaporator at low temperature (chiller unit)

Operation with water to the evaporator at low temperature (chiller unit)Operation with water to the evaporator at low temperature (chiller unit)

Operation with water to the evaporator at low temperature (chiller unit)

With temperatures below 5°C, it is good practice to operate with water and anti-freeze mixtures and alter the

relative safety devices (anti-freeze, etc.), which must be carried out by qualified authorised personnel or by the

manufacturer.

The glycol percentage in weight is determined depending on the desired temperature of the chilled water (see Table

5).

Minimum ambient temperature or liquid

outlet temperature (°C) 0 -5 -10

-15

-20

-25

-30

-35

-40

Freezing point (°C)

-

5

-

10

-

15

-

20

-

25

-

30

-

35

-

40

-

45

Anti

-

freeze

% in weight

Ethylene glycol

6

22

30

36

41

46

50

53

56

Propylene glycol

15

25

33

39

44

48

51

54

57

Temp

-

20

T

-

20°C

---

Temp

-

40

T

-

40°C

Temp

-

60

T

-

60°C

Tifoxite

40

50

60

63

69

73

-

Freezium

10

20

25

30

34

37

40

43

45

Pekasol 50

50

59

68

75

81

86

90

-

Table 5 - Freezing point for water-anti-freeze mixture

If environment temperatures are expected to be less than the freezing point of water, it

is important to use anti-freeze mixtures in the above mentioned percentages.

In the case of units with pump units applied in plants with a per 30% glycol, it is

necessary to request during the order phase a technical check to assess the compatibility

of the pumps and find the best solution which could require use of a specific hydraulic

module or the application of pumps with seals and special electric motors.

15

8.7

8.78.7

8.7 Operation with wate

Operation with wateOperation with wate

Operation with water to the condenser at low temperature (heat pump unit)

r to the condenser at low temperature (heat pump unit)r to the condenser at low temperature (heat pump unit)

r to the condenser at low temperature (heat pump unit)

The standard units are not designed to run with the flow of water to the condenser at too low a temperature (refer

to the technical booklet for the limits). In order to operate below this limit, the unit could require structural

modifications. In the event of these necessities, contact our company.

8.8

8.88.8

8.8 Discharge of the safety valves

Discharge of the safety valvesDischarge of the safety valves

Discharge of the safety valves

The cooling circuit is equipped with safety valves: some standards prescribe that the drain of such valves is taken

outside via a relevant pipe, which must have a diameter at least equal to that of the valve drain and its weight must

not burden the valve.

Warning: always convey the drain to areas where the jet cannot cause harm anyone.

9

99

9 CONNECTIONS FOR SPLIT UNITS

CONNECTIONS FOR SPLIT UNITSCONNECTIONS FOR SPLIT UNITS

CONNECTIONS FOR SPLIT UNITS

Warning: the following operations require pipes to be pressurised and soldered connections

that must be carried out by specialised personnel with the necessary qualifications according

to the applicable regulations.

The sizing and execution of the cooling lines affect the reliability and performance of the product. The following

paragraphs list a few suggestions when implementing the cooling lines, however, the installer is responsible for

ensuring they are executed correctly.

9.1

9.19.1

9.1 Cooling connections

Cooling connectionsCooling connections

Cooling connections

The LE (condensing) and LE/HP (reversible condensing) units with separate sections need to be connected to the

evaporator or condenser with refrigerant piping.

For the units in the version with separate sections, the route of the refrigerant piping depends on the positioning of

the lines and the structure of the building.

In any case, the pipes must be as short as possible in order to minimise the pressure drops and the amount of

refrigerant in the circuit; the maximum pipe length and maximum difference of level of the refrigerant piping are

indicated in table 3.

Our Company is happy to provide any information you require in this regard.

Sizes

SizesSizes

Sizes

9

99

9

-

--

-

15

1515

15

20

2020

20

-

--

-

26

2626

26

-

--

-

30

3030

30

Maximum permitted length of refrigerant piping

20 m

30 m

Maximum difference of level between the sections with

Celest+

at top level in

relation to the evaporating/condensing coil 15 m 30 m

Maximum difference of level between the sections with

Celest+

at bottom

level in relation to the evaporating/condensing coil 8 m 8 m

TABLE 3 - Maximum length and difference of level of refrigerant piping

9.2

9.29.2

9.2 Set

SetSet

Set-

--

-ups for the realisation of the refrigerant lines

ups for the realisation of the refrigerant linesups for the realisation of the refrigerant lines

ups for the realisation of the refrigerant lines

According to the position relative to the condensing and evaporating sections, there are some arrangements to

follow regarding the realisation of the refrigerant line.

The diameter of the pipes in relation to the size and version is indicated in Table 4.

Brazing should be carried out by qualified personnel taking care not to overheat the cocks and other components of

the machine's refrigerant circuit.

All the refrigerant lines should be insulated with insulating material a minimum of 9 mm thick; an absence of

insulation on the refrigerant lines can result in a loss of efficiency and the formation of condensation or ice on the

pipes, and can compromise correct operation of the unit.

9.3

9.39.3

9.3 LE versions: evaporating section at a level lower than that of the condensing section.

LE versions: evaporating section at a level lower than that of the condensing section.LE versions: evaporating section at a level lower than that of the condensing section.

LE versions: evaporating section at a level lower than that of the condensing section.

Siphons must be present on the vertical tracts of the intake line at at least every 5 metres to make return of the oil

to the compressor easier.

In the horizontal tracts of the intake line envision a gradient equal to at least 1% to favour oil return to the

compressor.

16

See fig. 6.

Fig. 6

9.4

9.49.4

9.4 LE versions: evaporating section at a level higher than that of the condensing section.

LE versions: evaporating section at a level higher than that of the condensing section.LE versions: evaporating section at a level higher than that of the condensing section.

LE versions: evaporating section at a level higher than that of the condensing section.

Realise a siphon on the intake line that is as high as the evaporator with the purpose of preventing the fall of liquid

refrigerant towards the compressor when the unit is at a standstill.

In the horizontal tracts of the intake line envision a gradient equal to at least 1% to favour oil return to the

compressor.

See fig. 7.

Fig. 7

9.5

9.59.5

9.5 LE/HP versions: evaporating/condensing section at a level lower than that of the

LE/HP versions: evaporating/condensing section at a level lower than that of the LE/HP versions: evaporating/condensing section at a level lower than that of the

LE/HP versions: evaporating/condensing section at a level lower than that of the

condensing/condenserless section.

condensing/condenserless section.condensing/condenserless section.

condensing/condenserless section.

Siphons must be present on the vertical tracts of the intake line at at least every 5 metres to make return of the oil

to the compressor easier.

Siphons must be present on the vertical tracts of the liquid (flash) line at at least every 5 metres to make return of

the oil to the compressor easier.

In the horizontal tracts of the intake line envision a gradient equal to at least 1% to favour oil return to the

compressor (as above).

See fig. 8

17

Fig. 8

9.6

9.69.6

9.6 LE/HP versions: evaporating/condensing section at a level higher than that of the

LE/HP versions: evaporating/condensing section at a level higher than that of the LE/HP versions: evaporating/condensing section at a level higher than that of the

LE/HP versions: evaporating/condensing section at a level higher than that of the

condensing/condenserless section.

condensing/condenserless section.condensing/condenserless section.

condensing/condenserless section.

Realise a siphon on the intake line that is as high as the evaporator with the purpose of preventing the fall of liquid

refrigerant towards the compressor when the unit is at a standstill.

Siphons must be present on the liquid (flash) line at at least every 5 metres to make return of the oil to the

compressor easier.

In the horizontal tracts of the intake line envision a gradient equal to at least 1% to favour oil return to the

compressor.

See fig. 9.

Fig. 9

Model

Model Model

Model

Celest+

Celest+Celest+

Celest+

Version

VersionVersion

Version

Length 10 m

Length 10 mLength 10 m

Length 10 m

Length 20 m

Length 20 mLength 20 m

Length 20 m

Length 30 m

Length 30 mLength 30 m

Length 30 m

Ø inlet mm

Ø flash

(mm) Ø inlet mm

Ø flash

(mm) Ø inlet mm

Ø flash

(mm)

9

99

9

LE:

LE/HP:

12 10 12 10 - -

15

1515

15

16 12 16 12 - -

20

2020

20

22 16 22 16 22 16

26

2626

26

22 16 22 16 22 16

30

3030

30

28 16 28 16 28 16

TABLE 4 - RECOMMENDED DIAMETER OF THE PIPING

9.7

9.79.7

9.7 Variation in capacity in relation to the length of the cooling lines

Variation in capacity in relation to the length of the cooling linesVariation in capacity in relation to the length of the cooling lines

Variation in capacity in relation to the length of the cooling lines

Figure 10 shows the indicative loss of cooling capacity for each metre of length of the cooling lines.

18

Fig. 10

9.8

9.89.8

9.8 Refrigerant load for LE and LE/HP units

Refrigerant load for LE and LE/HP unitsRefrigerant load for LE and LE/HP units

Refrigerant load for LE and LE/HP units

The units are pre-filled with a load of R-410A refrigerant at the factory; the load of refrigerant is calculated

theoretically for a 10m cooling line and has to be adjusted during initial start-up according to the volume of the

evaporating or evaporating/condensing coil connected, and according to the length of the connecting lines; the

load filled at the factory does not consider the volume of the evaporating/condensing coil connected because this is

not known a priori. Table 5 indicates the additional loads of refrigerant for each metre of a cooling line measuring

more than 10m.

Warning: the refrigerant loads are purely indicative and calculated theoretically. The actual

load could differ from that stipulated.

The refrigerant load will be confirmed and/or adjusted during the initial start-up (by the

authorised assistance centre)

Diameter (mm)

Gas (kg/m)

Liquid (kg/m)

12

0.007

0.074

16

0.014

0.139

18

0.019

0.182

22

0.029

0.285

28

0.045

0.445

TABLE 5 - Additional R-410A gas loads per metre of linear piping

10

1010

10 ELECTRICAL CONNECTIONS

ELECTRICAL CONNECTIONSELECTRICAL CONNECTIONS

ELECTRICAL CONNECTIONS

10.1

10.110.1

10.1 Overview

OverviewOverview

Overview

– The electrical connections must comply with the information shown on the wiring diagram attached to the unit

and the regulations in force in the place of installation.

– The earth connection is mandatory by law. The installer must connect the earth cable using the relevant PE

clamp on the earth bar situated in the electric control board.

– Verify that the power supply voltage corresponds to the nominal data of the unit (voltage, number of phases,

frequency) stated on the plate on the machine.

– The power supply voltage must not undergo variations over ±5% and the unbalance between the phases must

always be less than 2%. If this should not occur, contact our technical dept. in order to select the relevant

protections.

– Check that the line is connected with the correct sequence of the phases.

– To feed in the electrical cables, use the hole in the structural steelwork indicated by the relative label. The

power cord is fed in through the bottom part of the electric control board of the unit.

– The control circuit power supply derives from the power line via a transformer situated in the electric control

board. The control circuit is protected by relevant fuses.

-12%

-10%

-8%

-6%

-4%

-2%

0%

0 5 10 15 20 25 30

Loss of cooling capacity

Length of cooling lines [m]

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Swegon CELEST+ Maintenance Manual

Swegon CELEST+ Maintenance Manual

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